WO2016150128A1 - 一种塑封定子的制造方法、塑封定子和外转子电机 - Google Patents

一种塑封定子的制造方法、塑封定子和外转子电机 Download PDF

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Publication number
WO2016150128A1
WO2016150128A1 PCT/CN2015/090108 CN2015090108W WO2016150128A1 WO 2016150128 A1 WO2016150128 A1 WO 2016150128A1 CN 2015090108 W CN2015090108 W CN 2015090108W WO 2016150128 A1 WO2016150128 A1 WO 2016150128A1
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stator
magnetic conductive
plastic
conductive member
side wall
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PCT/CN2015/090108
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English (en)
French (fr)
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潘明攀
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中山大洋电机股份有限公司
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Publication of WO2016150128A1 publication Critical patent/WO2016150128A1/zh

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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/12—Stationary parts of the magnetic circuit
    • H02K1/16—Stator cores with slots for windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
    • H02K15/03—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets

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  • the invention relates to a manufacturing method of a plastic-sealed stator, a plastic-sealed stator and an outer-rotor motor, and belongs to the technical field of motors.
  • the existing outer rotor motor mainly comprises an inner stator and an outer rotor sleeved outside the inner stator, wherein the inner stator comprises a stator core, an end insulation and a coil winding, and the outer rotor comprises a casing sleeve and is mounted on the machine
  • a plurality of permanent magnets on the inner wall of the shell sleeve form a magnetic flux between the outer side surface of the tooth portion of the stator core and the inner side surface of the permanent magnet so that the outer rotor can be continuously rotated.
  • the outer side surface of the stator core is small, and the end insulation is attached to the end surface of the stator core, the outer side surface of the tooth portion of the stator core can receive the area of the magnetic flux emitted by the permanent magnet. It is smaller, thereby reducing the utilization rate of the permanent magnet, and the magnetic flux utilization of the permanent magnet is improved due to the lack of an effective magnetizing effect, and the outer rotor motor has low operating efficiency and high energy consumption.
  • stator core of the existing outer rotor motor is usually made of a stator punch punched from a single piece of silicon steel sheet, but the stator punch produced by this production method consumes a large amount of raw materials, silicon steel sheet.
  • the utilization rate is very low, which increases the production cost of the motor and reduces the market competitiveness of the motor products. These are not what the manufacturer expects.
  • An object of the present invention is to provide a method for manufacturing a molded stator, a molded stator and an outer rotor motor.
  • a method of manufacturing a plastically sealed stator characterized in that it consists of the following steps:
  • Step 1) fabricating a stator core: stacking a plurality of annular stator punches having an annular yoke portion and a plurality of stator teeth extending outward from an outer edge of the annular yoke portion to form a stator core;
  • Step 3) installing the magnetic conductive member the magnetic conductive member is set outside the stator core that has been wound around the coil winding, and the outer side wall of the stator tooth portion is in close contact with the inner side wall of the magnetic conductive member;
  • the end insulation of the above step 2) is injection molded on the end face of the stator core and exposes the outer side wall of the stator tooth portion.
  • the annular stator punching piece of the above step 1) is formed by winding a strip-shaped stator punching piece.
  • the width of the stator tooth portion is equal to the spacing between the adjacent two stator tooth portions. .
  • a molded stator comprising a stator core, an end insulation, a coil winding and a molding body, the stator core comprising an annular yoke and a plurality of stator teeth extending outward from an outer edge of the annular yoke, adjacent A wire groove is formed between the two stator tooth portions, the end portion is insulated and mounted on the end surface of the stator core, the coil winding is wound around the end insulation, and a ring-shaped magnetic conductive member is disposed outside the stator tooth portion, and the plastic sealing body is provided.
  • stator core, the end insulation, the coil winding and the magnetic conductive member are integrally connected, and the outer side wall of the stator tooth portion is in close contact with the inner side wall of the magnetic conductive member, and the outer side wall of the magnetic conductive member is exposed outside the plastic sealing body.
  • the magnetic conductive member has a cylindrical shape, and the magnetic conductive member comprises a plurality of magnetic conductive portions, each of the magnetic conductive portions respectively corresponding to one stator tooth portion, and the exposed outer side wall of each stator tooth portion and its corresponding magnetic conductive portion
  • the inner side walls are closely attached together, and the adjacent two magnetic conductive portions are connected together by a plurality of magnetic isolation bridges, and some of the plastic sealing bodies are filled in the gap formed between the adjacent two magnetic isolation bridges.
  • the axial height of the magnetically permeable portion described above is greater than the axial height of the stator teeth.
  • the width of the magnetically permeable portion described above is greater than the width of the stator teeth.
  • the slot width of the wire groove described above is greater than 3 mm.
  • An outer rotor motor comprises a rotating shaft, an outer rotor, a plastically sealed stator and a base, and a sleeve seat is protruded downward in the middle of the base, and a bearing is installed in the sleeve seat, the plastic sealing stator is set outside the sleeve seat, and the outer rotor sleeve is set Outside the molded stator, the rotating shaft is located inside the sleeve and supported on the bearing, and rotates One end of the shaft extends from the sleeve seat and is coupled to the outer rotor, characterized in that the molded stator is a molded stator as described in any one of claims 4 to 8.
  • the outer rotor described above includes a casing sleeve and a plurality of permanent magnets mounted on the inner wall of the casing sleeve, the axial height of the magnetically permeable member being equal to the axial height of the permanent magnet.
  • the invention has the following effects:
  • the magnetic conductive component is set on the outer surface of the stator tooth portion, and the stator core, the end insulation, the coil winding and the magnetic conductive component are integrally connected by the plastic sealing body, and the outer side wall of the stator tooth portion is closely attached to the inner side wall of the magnetic conductive component.
  • the outer side wall of the magnetic conductive member is exposed outside the plastic sealing body, so that the stator core can receive the magnetic flux emitted by the permanent magnet in a wider range, forming a magnetic collecting effect, improving the utilization ratio of the permanent magnet, thereby improving the efficiency of the motor;
  • the width of the stator tooth portion is equal to the spacing between the adjacent two stator tooth portions, and the structure is closely arranged, thereby minimizing the amount of silicon steel sheet to save production cost;
  • the magnetic conductive member comprises a plurality of magnetic conductive portions, each of the magnetic conductive portions respectively corresponding to one stator tooth portion, and the exposed outer side wall of each stator tooth portion is closely attached to the inner side wall of the corresponding magnetic conductive portion, adjacent to each other
  • the two magnetic conducting portions are connected together by a plurality of magnetic isolation bridges, thereby effectively avoiding a short circuit between two adjacent magnetic poles, and connecting the plurality of magnetic conductive portions into a whole through the magnetic isolation bridge, which is convenient for production and installation.
  • Part of the plastic sealing body is filled in the gap formed between the adjacent two magnetic isolation bridges, thereby effectively increasing the bonding force between the magnetic conductive member and the stator core, and has high structural strength and high reliability;
  • the axial height of the magnetic conductive portion is larger than the axial height of the stator tooth portion, and the width of the magnetic conductive portion is larger than the width of the stator tooth portion, and the magnetic core can receive the magnetic field emitted by the permanent magnet through the magnetic conductive portion. Passing, forming a magnetic concentrating effect, improving the utilization rate of the permanent magnet, thereby improving the efficiency of the motor;
  • the slot width of the welt groove is greater than 3 mm. Since the stator core of the present invention comprises a plurality of annular stator punches stacked together, the annular stator punch is formed by winding a strip stator strip, so the welt groove of The width of the notch is greater than 3 mm, which is larger than the width of the groove of the existing stator core, which makes the subsequent winding simpler, effectively improves assembly efficiency and reduces labor cost;
  • the outer rotor comprises a casing sleeve and a plurality of permanent magnets mounted on the inner wall of the casing sleeve, the axial height of the magnetic conductive member is equal to the axial height of the permanent magnet, and the stator core can be made through the magnetic guiding portion
  • the magnetic flux emitted by the permanent magnets is received in a wide range to form a collecting magnetic effect, which improves the utilization rate of the permanent magnets, thereby improving the efficiency of the motor.
  • Figure 1 is a perspective view of a molded stator in an embodiment
  • Figure 2 is a perspective view of the molded stator in which the molded body is not attached in the embodiment
  • Figure 3 is an exploded view of Figure 2;
  • Figure 4 is a schematic structural view of an annular stator punching piece in the embodiment
  • Figure 5 is a schematic structural view of a strip-shaped stator punching piece in the embodiment
  • Figure 6 is a perspective view of the outer rotor motor in the embodiment
  • Figure 7 is an exploded view of the outer rotor motor in the embodiment
  • Figure 8 is a plan view of the outer rotor motor in the embodiment.
  • Figure 9 is a cross-sectional view taken along line A-A of Figure 8.
  • Embodiment 1 is a manufacturing method of a plastic sealed stator, which is composed of the following steps:
  • Step 1) Making a stator core: stacking a plurality of annular stator punches 101 with annular yoke 11 and a plurality of stator teeth 12 projecting outward from the outer edge of the annular yoke 11 to form a stator core 1;
  • Step 3) mounting the magnetic conductive member the magnetic conductive member 5 is fitted on the outer surface of the stator core 1 on which the coil winding 3 has been wound, and the outer side wall of the stator tooth portion 12 is in close contact with the inner side wall of the magnetic conductive member 5;
  • Step 4) Plastic sealing: integrally molding the stator core 1 with the magnetic conductive member 5 formed in the step 3) to form a plastic body 4, and the stator core 1, the end portion insulation 2, the coil winding 3 and the guide through the plastic sealing body 4.
  • the magnetic members 5 are joined together, and the outer side walls of the magnetic conductive members 5 are exposed outside the molded body 4.
  • Embodiment 2 As shown in FIG. 1 , FIG. 2 , FIG. 3 , FIG. 4 and FIG. 5 , the present invention is a plastic sealed stator including a stator core 1 , an end insulation 2 , a coil winding 3 , and a molded body 4 .
  • the stator core 1 includes an annular yoke portion 11 and a plurality of stator teeth 12 projecting outwardly from an outer edge of the annular yoke portion 11, and a wire groove 13 is formed between the adjacent two stator tooth portions 12, and the end portion is formed
  • the insulation 2 is injection-molded on the end surface of the stator core 1 and exposes the outer side wall of the stator tooth portion 12, and the coil winding 3 is wound around the end insulation 2, which further includes an annular magnetic conductive member 5 for guiding the magnetic field.
  • the piece 5 is sleeved on the outside of the stator tooth portion 12, and the exposed outer side wall of the stator tooth portion 12 is in close contact with the inner side wall of the magnetic conductive member 5, and the stator core 1, the end portion is insulated, and the coil winding 3 is sealed by the injection molding body 4.
  • the magnetic conductive member 5 is integrally connected to the magnetic conductive member 5, and the outer side wall of the magnetic conductive member 5 is exposed outside the plastic sealing body 4.
  • the stator core 1 includes a plurality of annular stator punching pieces 101 stacked together, and the annular stator punching piece 101 is formed by winding a strip-shaped stator punching piece 102, and the annular stator punching piece 101 is embedded in the groove 13
  • the slot width C is greater than 3 mm.
  • two strip-shaped stator punching pieces 102 are symmetrically staggered, wherein the stator tooth portions 12 on one strip-shaped stator punching piece 102 extend into the other strip-shaped stator punching piece 102 adjacent to each other. Inside the gap formed between the two stator tooth portions 12, the width A of the stator tooth portion 12 and the distance B between the adjacent two stator tooth portions 12 are equal, and the design without gaps can minimize the raw silicon steel sheet. The amount used to reduce production costs.
  • the magnetic conductive member 5 has a cylindrical shape, and the magnetic conductive member 5 includes a plurality of magnetic conductive portions 51.
  • Each of the magnetic conductive portions 51 respectively corresponds to one stator tooth portion 12, and the exposed outer side wall of each stator tooth portion 12 is
  • the inner side walls of the corresponding magnetic conductive portions 51 are closely attached together, and the two adjacent magnetic conductive portions 51 are connected by four magnetic bridges 52, wherein the two magnetic isolation bridges 52 are respectively located adjacent to the two guides.
  • the other end between the magnetic portions 51 and the other two magnetic bridges 52 are located at positions between the magnetic bridges 52 at both ends, and are evenly arranged at intervals.
  • the partially molded body 4 is filled in the gap 53 formed between the two adjacent magnetic bridges 52, effectively increasing the bonding force between the magnetic conductive member 5 and the stator core 1, and has high structural strength and high reliability.
  • the axial height H1 of the magnetic conductive portion 51 is larger than the axial height H2 of the stator tooth portion 12.
  • the width of the magnetic conductive portion 51 is larger than the width of the stator tooth portion 12, and the magnetic core portion 1 can receive the magnetic flux emitted by the permanent magnet 72 through the magnetic conductive portion 51 to form a magnetic concentrating effect, thereby lifting the permanent magnet. Utilization, thereby increasing the efficiency of the motor.
  • Embodiment 3 As shown in FIG. 1 to FIG. 9, the present embodiment is an outer rotor motor including a rotating shaft 6, an outer rotor 7, a molded stator 8 and a base 9, and a sleeve seat 91 is extended downward in the middle of the base 9.
  • a bearing 10 is mounted on the sleeve seat 91.
  • the molded stator 8 is sleeved on the outside of the sleeve seat 91.
  • the outer rotor 7 is sleeved on the outside of the molded stator 8.
  • the shaft 6 is located inside the sleeve seat 91 and supported by the sleeve.
  • the molded stator 8 includes a stator core 1, an end insulation 2, a coil winding 3 and a molding body 4,
  • the stator core 1 includes an annular yoke 11 and a plurality of stator teeth 12 projecting outwardly from the outer edge of the annular yoke 11, and a wire groove 13 is formed between the adjacent two stator teeth 12, and the end insulation 2 is installed.
  • the outer rotor 7 includes a casing sleeve 71 and a plurality of permanent magnets 72 mounted on the inner wall of the casing sleeve 71.
  • the casing sleeve 71 is made of a metal material.
  • the axial height H1 of the magnetic conductive member 5 is equal to the axial height H3 of the permanent magnet 72, and the axial height H1 of the magnetic conductive member 5 is greater than the axial height H2 of the stator tooth portion 12.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Iron Core Of Rotating Electric Machines (AREA)
  • Insulation, Fastening Of Motor, Generator Windings (AREA)
  • Manufacture Of Motors, Generators (AREA)

Abstract

一种塑封定子的制造方法、塑封定子和外转子电机，在定子齿部（12）外面套装有环形的导磁件（5），塑封体（4）把定子铁芯（1）、端部绝缘（2）、线圈绕组（3）和导磁件（5）连结成一体，定子齿部（12）的外侧壁贴紧导磁件（5）的内侧壁，导磁件（5）的外侧壁裸露在塑封体（4）的外面，使定子铁芯（1）可以更大范围地接收由永磁体（72）发出的磁通，形成聚磁效应，提升永磁体（72）的利用率，从而提升电机的效率。

Description

一种塑封定子的制造方法、塑封定子和外转子电机 技术领域：
本发明涉及一种塑封定子的制造方法、塑封定子和外转子电机，属于电机技术领域。
背景技术：
现有的外转子电机，主要包括内定子和套设于所述内定子外面的外转子，其中内定子包括定子铁芯、端部绝缘和线圈绕组，外转子包括机壳套筒和安装在机壳套筒内壁上的若干永磁体，在定子铁芯的齿部的外侧面与永磁体的内侧面之间形成磁通，以使外转子可以不停地转动。但是由于在定子铁芯的外侧面面积较小，并且在定子铁芯的端面上安装有端部绝缘等原因，使定子铁芯的齿部的外侧面能接收永磁体发出的磁通的面积变得更小，从而降低永磁体的利用率，并且由于缺乏有效的聚磁效应来提升永磁体的磁通利用率，外转子电机的运行效率低，能耗高。
同时，现有外转子电机的定子铁芯通常是由整块的硅钢片冲压而成的定子冲片做成，但是采用这种生产方式制造出来的定子冲片，原材料的消耗十分大，硅钢片的利用率十分低下，使电机的生产成本提高，降低电机产品的市场竞争力，这些都不是生产厂家所期望的。
发明内容：
本发明的目的是提供一种塑封定子的制造方法、塑封定子和外转子电机，通过在定子铁芯的齿部外面套装导磁件，使定子铁芯可以更大范围地接收由永磁体发出的磁通，形成聚磁效应，提升永磁体的利用率，从而提升电机的效率。
本发明的目的是通过下述技术方案予以实现的。
一种塑封定子的制造方法，其特征在于：它由如下步骤组成：
步骤一)制作定子铁芯：将若干片带有环形轭部和从环形轭部外侧边缘上往外伸出的若干定子齿部的环形定子冲片叠压组装在一起形成定子铁芯；
步骤二)绕线：在定子铁芯两端安装端部绝缘，然后把线圈绕组卷绕安装 在定子齿部的端部绝缘上；
步骤三)安装导磁件：把导磁件套装在已经卷绕线圈绕组的定子铁芯外面，并且使定子齿部外侧壁与导磁件内侧壁紧密接触；
步骤四)塑封：将步骤三)中形成的带有导磁件的定子铁芯整体注塑形成塑封体，通过塑封体把定子铁芯、端部绝缘、线圈绕组和导磁件连结成一体，并且使导磁件的外侧壁裸露在塑封体的外面。
上述所述步骤二)的端部绝缘是注塑安装在定子铁芯的端面上，并且使定子齿部的外侧壁裸露。
上述所述的步骤一)的环形定子冲片是由条形定子冲片卷圆而成，在条形定子冲片中，定子齿部的宽度与相邻两个定子齿部之间的间距相等。
一种塑封定子，包括定子铁芯、端部绝缘、线圈绕组和塑封体，所述的定子铁芯包括环形轭部和从环形轭部外侧边缘上往外伸出的若干定子齿部，相邻的两个定子齿部之间形成嵌线槽，端部绝缘安装在定子铁芯的端面上，线圈绕组卷绕安装在端部绝缘上，在定子齿部外面套装有环形的导磁件，塑封体把定子铁芯、端部绝缘、线圈绕组和导磁件连结成一体，定子齿部的外侧壁贴紧导磁件的内侧壁，导磁件的外侧壁裸露在塑封体的外面。
上述所述的导磁件呈圆筒状，导磁件包括若干个导磁部，每个导磁部分别对应着一个定子齿部，每个定子齿部裸露的外侧壁与其对应的导磁部的内侧壁紧贴在一起，相邻的两个导磁部之间通过若干隔磁桥连接在一起，部分塑封体填充在相邻两个隔磁桥之间形成的缝隙里面。
上述所述的导磁部的轴向高度大于定子齿部的轴向高度。
上述所述的导磁部的宽度大于定子齿部的宽度。
上述所述的嵌线槽的槽口宽度大于3mm。
一种外转子电机，包括转轴、外转子、塑封定子和底座，在底座中间往下伸出套筒座，在套筒座里面安装有轴承，塑封定子套装在套筒座外面，外转子套设于所述塑封定子外面，转轴位于套筒座里面并且支承在所述的轴承上，转 轴一端从套筒座伸出与外转子连接在一起，其特征在于：所述的塑封定子是权利要求4至8任一项所描述的塑封定子。
上述所述的外转子包括机壳套筒和安装在机壳套筒内壁上的若干永磁体，导磁件的轴向高度等于所述永磁体的轴向高度。
本发明与现有技术相比，具有如下效果：
1)把导磁件套装在定子齿部外面，通过塑封体把定子铁芯、端部绝缘、线圈绕组和导磁件连结成一体，定子齿部的外侧壁贴紧导磁件的内侧壁，导磁件的外侧壁裸露在塑封体的外面，使定子铁芯可以更大范围地接收由永磁体发出的磁通，形成聚磁效应，提升永磁体的利用率，从而提升电机的效率；
2)端部绝缘是注塑安装在定子铁芯的端面上并且使定子齿部的外侧壁裸露，相比于现有把已经成型的端部绝缘安装在定子铁芯的端面上，本发明的生产工艺更加简单，端部绝缘与定子铁芯之间的结合力更强，不易松动或者脱落，可靠性更高；
3)在条形定子冲片中，定子齿部的宽度与相邻两个定子齿部之间的间距相等，结构排列紧密，能最大程度上地减小硅钢片的用量，以节省生产成本；
4)导磁件包括若干个导磁部，每个导磁部分别对应着一个定子齿部，每个定子齿部裸露的外侧壁与其对应的导磁部的内侧壁紧贴在一起，相邻的两个导磁部之间通过若干隔磁桥连接在一起，有效避免相邻两个磁极之间的短路，并且通过隔磁桥把多个导磁部连结成一个整体，方便生产和安装，部分塑封体填充在相邻两个隔磁桥之间形成的缝隙里面，有效增加导磁件与定子铁芯的结合力，结构强度大，可靠性高；
5)导磁部的轴向高度大于定子齿部的轴向高度，导磁部的宽度大于定子齿部的宽度，通过导磁部使定子铁芯可以更大范围地接收由永磁体发出的磁通，形成聚磁效应，提升永磁体的利用率，从而提升电机的效率；
6)嵌线槽的槽口宽度大于3mm，由于本发明的定子铁芯包括若干层叠在一起的环形定子冲片，环形定子冲片是由条形定子冲片卷圆而成，因此嵌线槽的 槽口宽度大于3mm，相比于现有定子铁芯的嵌线槽槽口宽度更大，使之后的绕线更加简单，有效提高装配效率，降低人力成本；
7)外转子包括机壳套筒和安装在机壳套筒内壁上的若干永磁体，导磁件的轴向高度等于所述永磁体的轴向高度，通过导磁部使定子铁芯可以更大范围地接收由永磁体发出的磁通，形成聚磁效应，提升永磁体的利用率，从而提升电机的效率。
附图说明：
图1是实施例中塑封定子的立体图；
图2是实施例中未安装塑封体的塑封定子的立体图；
图3是图2的分解图；
图4是实施例中环形定子冲片的结构示意图；
图5是实施例中条形定子冲片的结构示意图；
图6是实施例中外转子电机的立体图；
图7是实施例中外转子电机的分解图；
图8是实施例中外转子电机的俯视图；
图9是图8中A-A剖视图。
具体实施方式：
下面通过具体实施例并结合附图对本发明作进一步详细的描述。
实施例一：本实施例是一种塑封定子的制造方法，它由如下步骤组成：
步骤一)制作定子铁芯：将若干片带有环形轭部11和从环形轭部11外侧边缘上往外伸出的若干定子齿部12的环形定子冲片101叠压组装在一起形成定子铁芯1；
步骤二)绕线：在定子铁芯1两端安装端部绝缘2，然后把线圈绕组3卷绕安装在定子齿部12的端部绝缘2上；
步骤三)安装导磁件：把导磁件5套装在已经卷绕线圈绕组3的定子铁芯1外面，并且使定子齿部12外侧壁与导磁件5内侧壁紧密接触；
步骤四)塑封：将步骤三)中形成的带有导磁件5的定子铁芯1整体注塑形成塑封体4，通过塑封体4把定子铁芯1、端部绝缘2、线圈绕组3和导磁件5连结成一体，并且使导磁件5的外侧壁裸露在塑封体4的外面。
实施例二：如图1、图2、图3、图4和图5所示，本发明是一种塑封定子，包括定子铁芯1、端部绝缘2、线圈绕组3和塑封体4，所述的定子铁芯1包括环形轭部11和从环形轭部11外侧边缘上往外伸出的若干定子齿部12，相邻的两个定子齿部12之间形成嵌线槽13，把端部绝缘2注塑安装在定子铁芯1的端面上并且使定子齿部12的外侧壁裸露，把线圈绕组3卷绕安装在端部绝缘2上，它还包括环形的导磁件5，把导磁件5套装在定子齿部12外面，定子齿部12裸露的外侧壁与导磁件5的内侧壁紧贴在一起，通过注塑塑封体4把定子铁芯1、端部绝缘2、线圈绕组3和导磁件5连结成一体，导磁件5的外侧壁裸露在塑封体4的外面。
其中所述的定子铁芯1包括若干层叠在一起的环形定子冲片101，环形定子冲片101是由条形定子冲片102卷圆而成，环形定子冲片101中，嵌线槽13的槽口宽度C大于3mm。在同一块长方形的原料硅钢板上，两个条形定子冲片102对称交错排布，其中一个条形定子冲片102上的定子齿部12伸入到另一个条形定子冲片102相邻两个定子齿部12之间形成的间隙里面，定子齿部12的宽度A与相邻两个定子齿部12之间的间距B相等，无间隙的设计，能最大程度地减小原料硅钢片的用量，以降低生产成本。
所述的导磁件5呈圆筒状，导磁件5包括若干个导磁部51，每个导磁部51分别对应着一个定子齿部12，每个定子齿部12裸露的外侧壁与其对应的导磁部51的内侧壁紧贴在一起，相邻的两个导磁部51之间通过4个隔磁桥52连接在一起，其中2个隔磁桥52分别位于相邻两个导磁部51之间的端部，另外2个隔磁桥52位于两端部的隔磁桥52之间的位置上，呈间隔均匀排布。部分塑封体4填充在相邻两个隔磁桥52之间形成的缝隙53里面，有效增加导磁件5与定子铁芯1的结合力，结构强度大，可靠性高.
导磁部51的轴向高度H1大于定子齿部12的轴向高度H2。所述导磁部51的宽度大于定子齿部12的宽度，通过导磁部51使定子铁芯1可以更大范围地接收由永磁体72发出的磁通，形成聚磁效应，提升永磁体的利用率，从而提升电机的效率。
实施例三：如图1至图9所示，本实施例是一种外转子电机，包括转轴6、外转子7、塑封定子8和底座9，在底座9中间往下伸出套筒座91，在套筒座91里面安装有轴承10，塑封定子8套装在套筒座91外面，外转子7套设于所述塑封定子8外面，转轴6位于套筒座91里面并且支承在所述的轴承10上，转轴6一端从套筒座91伸出与外转子7连接在一起，所述的塑封定子8包括定子铁芯1、端部绝缘2、线圈绕组3和塑封体4，所述的定子铁芯1包括环形轭部11和从环形轭部11外侧边缘上往外伸出的若干定子齿部12，相邻的两个定子齿部12之间形成嵌线槽13，端部绝缘2安装在定子铁芯1的端面上，线圈绕组3卷绕安装在端部绝缘2上，在定子齿部12外面套装有环形的导磁件5，塑封体4把定子铁芯1、端部绝缘2、线圈绕组3和导磁件5连结成一体，定子齿部12的外侧壁贴紧导磁件5的内侧壁，导磁件5的外侧壁裸露在塑封体4的外面。所述的外转子7包括机壳套筒71和安装在机壳套筒71内壁上的若干永磁体72，所述的机壳套筒71采用金属材料制成。导磁件5的轴向高度H1等于所述永磁体72的轴向高度H3，导磁件5的轴向高度H1大于定子齿部12的轴向高度H2。
以上实施例为本发明的较佳实施方式，但本发明的实施方式不限于此，其他任何未背离本发明的精神实质与原理下所作的改变、修饰、替代、组合、简化，均为等效的置换方式，都包含在本发明的保护范围之内。

Claims (10)

  1. 一种塑封定子的制造方法，其特征在于：它由如下步骤组成：
    步骤一)制作定子铁芯：将若干片带有环形轭部(11)和从环形轭部(11)外侧边缘上往外伸出的若干定子齿部(12)的环形定子冲片(101)叠压组装在一起形成定子铁芯(1)；
    步骤二)绕线：在定子铁芯(1)两端安装端部绝缘(2)，然后把线圈绕组(3)卷绕安装在定子齿部(12)的端部绝缘(2)上；
    步骤三)安装导磁件：把导磁件(5)套装在已经卷绕线圈绕组(3)的定子铁芯(1)外面，并且使定子齿部(12)外侧壁与导磁件(5)内侧壁紧密接触；
    步骤四)塑封：将步骤三)中形成的带有导磁件(5)的定子铁芯(1)整体注塑形成塑封体(4)，通过塑封体(4)把定子铁芯(1)、端部绝缘(2)、线圈绕组(3)和导磁件(5)连结成一体，并且使导磁件(5)的外侧壁裸露在塑封体(4)的外面。
  2. 根据权利要求1所述的一种塑封定子的制造方法，其特征在于：所述步骤二)的端部绝缘(2)是注塑安装在定子铁芯(1)的端面上，并且使定子齿部(12)的外侧壁裸露。
  3. 根据权利要求1或2所述的一种塑封定子的制造方法，其特征在于：所述的步骤一)的环形定子冲片(101)是由条形定子冲片(102)卷圆而成，在条形定子冲片(102)中，定子齿部(12)的宽度与相邻两个定子齿部(12)之间的间距相等。
  4. 一种塑封定子，包括定子铁芯(1)、端部绝缘(2)、线圈绕组(3)和塑封体(4)，所述的定子铁芯(1)包括环形轭部(11)和从环形轭部(11)外侧边缘上往外伸出的若干定子齿部(12)，相邻的两个定子齿部(12)之间形成嵌线槽(13)，端部绝缘(2)安装在定子铁芯(1)的端面上，线圈绕组(3)卷绕安装在端部绝缘(2)上，其特征在于：在定子齿部(12)外面套装有环形 的导磁件(5)，塑封体(4)把定子铁芯(1)、端部绝缘(2)、线圈绕组(3)和导磁件(5)连结成一体，定子齿部(12)的外侧壁贴紧导磁件(5)的内侧壁，导磁件(5)的外侧壁裸露在塑封体(4)的外面。
  5. 根据权利要求4所述的一种塑封定子，其特征在于：所述导磁件(5)呈圆筒状，导磁件(5)包括若干个导磁部(51)，每个导磁部(51)分别对应着一个定子齿部(12)，每个定子齿部(12)裸露的外侧壁与其对应的导磁部(51)的内侧壁紧贴在一起，相邻的两个导磁部(51)之间通过若干隔磁桥(52)连接在一起，部分塑封体(4)填充在相邻两个隔磁桥(52)之间形成的缝隙(53)里面。
  6. 根据权利要求5所述的一种塑封定子，其特征在于：所述导磁部(51)的轴向高度大于定子齿部(12)的轴向高度。
  7. 根据权利要求5或6所述的一种塑封定子，其特征在于：所述导磁部(51)的宽度大于定子齿部(12)的宽度。
  8. 根据权利要求4或5或6所述的一种塑封定子，其特征在于：嵌线槽(13)的槽口宽度大于3mm。
  9. 一种外转子电机，包括转轴(6)、外转子(7)、塑封定子(8)和底座(9)，在底座(9)中间往下伸出套筒座(91)，在套筒座(91)里面安装有轴承(10)，塑封定子(8)套装在套筒座(91)外面，外转子(7)套设于所述塑封定子(8)外面，转轴(6)位于套筒座(91)里面并且支承在所述的轴承(10)上，转轴(6)一端从套筒座(91)伸出与外转子(7)连接在一起，其特征在于：所述的塑封定子(8)是权利要求4至8任一项所描述的塑封定子。
  10. 根据权利要求9所述的一种外转子电机，其特征在于：所述的外转子(7)包括机壳套筒(71)和安装在机壳套筒(71)内壁上的若干永磁体(72)，导磁件(5)的轴向高度等于所述永磁体(72)的轴向高度。
PCT/CN2015/090108 2015-03-20 2015-09-21 一种塑封定子的制造方法、塑封定子和外转子电机 WO2016150128A1 (zh)

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